Capacitor containing aluminum anode foil anodized in low water content glycerine-phosphate electrolyte without a pre-anodizing hydaration step

ABSTRACT

A capacitor comprising an aluminum anode and a dielectric layer comprising phosphate doped aluminum oxide and process for making the capacitor. The capacitor has a CV Product of at least 9 μF−V/cm 2  at 250 volts. Furthermore, the capacitor is formed by the process of: forming an aluminum plate; contacting the plate with an anodizing solution comprising glycerine, 0.1 to 1.0%, by weight, water and 0.01 to 0.5%, by weight, orthophosphate; applying a voltage to the aluminum plate and determining an initial current; maintaining the first voltage until a first measured current is no more than 50% of the initial current; increasing the voltage and redetermining the initial current; maintaining the increased voltage until a second measured current is no more than 50% of the redetermined initial current, and continuing the increasing of the voltage and maintaining the increased voltage until a final voltage is achieved.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present invention is a divisional application of pending U.S. patentapplication Ser. No. 11/099,917 filed Mar. 6, 2005 which is a divisionalapplication of U.S. patent application Ser. No. 10/390,529 filed Mar.17, 2003 which is now issued as U.S. Pat. No. 7,125,610.

BACKGROUND OF THE INVENTION

The present invention is related to an electrolyte solution foranodizing aluminum anode foil for use in electrolytic capacitors and thecapacitors containing this anode foil.

We have found that low water content variations of the glycerine andorthophosphate-containing electrolytes described in U.S. Pat. No.6,409,905, which is incorporated herein by reference thereto, may beused for the anodization of aluminum foil to voltages sufficiently highto facilitate the use of the aforementioned foil in intermediate andhigh voltage electrolytic capacitors.

Previously, the maximum anodizing voltage obtainable from the aqueousphosphate solutions traditionally used to anodize aluminum capacitorfoil for applications requiring extreme foil stability and oxidehydration resistance was about 220 volts, as stated in U.S. Pat. No.3,733,291. The corrosion of the foil being anodized in aqueous phosphatesolutions increases with the anodizing voltage and is sufficientlysevere to result in dielectric failure above about 220 volts. Thecorrosion by-products formed during aluminum foil anodizing in aqueousphosphate solutions must be removed from the solution via filtering,etc., or they will deposit upon the foil and anodizing tank componentsin amounts sufficient to interfere with the anodizing process.

The difficulties encountered with aqueous phosphate anodizing ofaluminum foil for use in relatively low voltage capacitors are suchthat, in spite of the superior electrical stability of foil anodized inphosphate solutions nearly all of the low voltage foil produced today isanodized in non-phosphate solutions with the exception of a relativelysmall amount of phosphate which may be present to help impart hydrationresistance. Due to the voltage limitations of aqueous phosphateanodizing solutions mentioned above, intermediate and high voltagecapacitor foils have not traditionally been anodized in aqueousphosphate solutions.

Aluminum electrolytic capacitors for use at intermediate voltagestypically contain anode foil hydrated by passing the foil through a hotwater bath prior to anodizing, as defined in U.S. Pat. No. 4,582,574.These capacitors are typically for use at voltages from 150 to 250 voltsand contain anode foil anodized to about 200 to 350 volts. Thispre-anodizing hydration step is carried out in order to reduce theamount of electric current required to form the anodic oxide dielectriclayer and is normally applied to foils to be anodized to 200 volts andabove, as described in U.S. Pat. No. 4,481,073. By carefully adjustingthe parameters of the pre-anodizing hydration process, as described inU.S. Pat. No. 4,242,575, the hydration process may be successfullyemployed with foils which are anodized to voltages significantly lessthan 200 volts. The energy savings associated with the pre-anodizinghydration process is sufficiently great that the vast majority ofaluminum foil manufactured today is processed in this manner.

The crystallinity of the anodic oxide present on aluminum anode foil isanother factor directly determining the cost of the foil for a givenrating of capacitor. Crystalline anodic aluminum oxide has a higherwithstanding voltage per unit thickness than does amorphous anodicaluminum oxide. As a result of the higher withstanding voltage ofcrystalline oxide, only about 10 angstroms of crystalline oxide isrequired to support each volt of applied field during anodizing ascompared with approximately 14 angstroms for each volt of applied fieldfor amorphous oxide. As a result of the higher withstanding voltage ofcrystalline anodic aluminum oxide, the capacitance of anode foil coatedwith crystalline oxide may be as much as about 40% higher than anodefoil anodized to the same voltage but coated with amorphous oxide.

Crystalline anodic aluminum oxide may be readily produced by anodizingaluminum anode foil in solutions containing salts of dicarboxylic acidsas the primary ionogen, as described in U.S. Pat. No. 4,481,084. Anodicoxide formation in solutions of dicarboxylic acid salts (generally at70-95° C.) may be combined with a pre-anodizing foil hydration step toachieve a very significant savings in both energy and foil consumed perunit capacitance at a given anodizing voltage.

Hydration resistance, which is an important consideration for foil usedin electrolytic capacitors, may be enhanced by the inclusion of a smallamount of an alpha-hydroxy carboxylic acid (such as tartaric acid orcitric acid) in the anodizing electrolyte solution, as described in U.S.Pat. No. 4,481,084. The tendency of anodic aluminum oxide to absorbwater, forming a variety of hydrated species having impaired dielectricproperties appears to be, at least in part, a function of the hydrationstatus of the outermost portion of the anodic oxide at the end of theanodizing process. Lilienfeld, in U.S. Pat. No. 2,826,724 states that“it is the hydration stratum of the oxide film, adjacent thefilm-electrolyte interface, which causes most of the power loss; andthat the progressive development of hydration at the interface causesthe aforesaid instability.”

Alwitt, in U.S. Pat. No. 3,733,291, describes a method of removing theresidual hydration layer from the outer surface of anodized aluminumcapacitor foil which has been exposed to a pre-anodizing hydration step(Alwitt refers to this as a “preboil”) prior to anodizing in order toconserve electrical energy during anodizing. Alwitt employs a dilutephosphoric acid solution, generally with a small chromate content (toinhibit corrosion), to dissolve the outer, hydration layer.

In addition to the problems associated with the residual hydration layeron anodized foil, which has been processed through a pre-anodizinghydration or preboil step prior to anodizing, there exists anotherpotential problem with the stability of the anodic oxide grown onpreboiled aluminum foil. The formation of the anodic oxide on preboiledfoil takes place via a dehydration reaction in which the layer ofpseudoboehmite (i.e. hydration product) is progressively dehydrated fromthe foil-oxide interface outward. Apparently, the dehydration does nottake place through the ejection of water molecules but rather throughthe ejection of hydrogen ions and the liberation of oxygen gas withinthe body of the oxide. The liberated oxygen gas may become trappedwithin the anodic oxide, rendering the oxide susceptible to cracking anddielectric failure in service. This topic is treated well in thearticle, entitled: “Trapped Oxygen in Aluminum Oxide Films and ItsEffect on Dielectric Stability”, by Walter J. Bernard and Philip G.Russell (Journal of the Electrochemical Society, Volume 127, number 6,June 1980, pages 1256-1261).

Stevens and Shaffer describe a method of determining the concentrationof oxide flaws as a function of distance from the metal-oxide interfacefor trapped-oxygen flaws which are exposed via thermal relaxation stepsfollowed by re-anodizing under carefully controlled and monitoredconditions (“Defects in Crystalline Anodic Aluminum”, by J. L. Stevensand J. S. Shaffer, Journal of the Electrochemical Society, volume 133,number 6, June 1986, pages 1160-1162).

Stabilization processes have been developed which tend to expose andrepair trapped oxygen flaws (in anodic oxide films on preboiled foils)as well as impart hydration resistance to the oxide film. Examples ofthese processes are described in U.S. Pat. Nos. 4,113,579 and 4,437,946.

For maximum anodic oxide film stability on aluminum foil, it isdesirable to form the anodic film in a phosphate solution and, again,for maximum stability (i.e., freedom from trapped oxygen flaws) the foilshould not be preboiled prior to the anodizing process.

The skilled artisan has therefore been limited in the ability to formoxides on the anode at high voltage, particularly with phosphateincorporation into the oxide layer.

BRIEF SUMMARY OF THE INVENTION

It is object of the present invention to provide an improved process foranodizing aluminium.

It is another object of the present invention to provide a process foranodizing an aluminum surface at high voltage, over 220 volts, withoutpre-boil or surface hydration, while still incorporating the advantagesoffered by phosphate in the oxide layer. This has previously beenunavailable to those of ordinary skill in the art.

It is another object of the present invention to provide an anodizingsolution which can provide a capacitor with a capacitance above 9μf−V/cm² at 250 V which was previously not available to the art.

A particular feature of the present invention is that one variation ofthe electrolyte family described in U.S. Pat. No. 6,409,905, i.e,glycerine-based electrolytes containing orthophosphate as the anionicportion of the ionogen may be used to anodize aluminum foil to highvoltages, for example 1000 volts. The use of these electrolytes, then,overcomes the limitations of traditional aqueous phosphate electrolytesin so far as the maximum anodizing voltage achievable with aqueouselectrolytes (i.e. 220 volts, as given in U.S. Pat. No. 3,733,291) maybe exceeded by many hundreds of volts. Furthermore, the use of low-watercontent glycerine-based, orthophosphate-containing electrolyte solutionsfor anodizing aluminum avoids the corrosion of the anode foil byessentially eliminating the subsequent formation of aluminum phosphateprecipitates which normally occurs during the anodization.

Another particular feature is that when the low-water content, glycerinebased electrolytes of U.S. Pat. No. 6,409,905 are used to anodizealuminum foil which has not been preboiled (i.e. relativelyhydrated-oxide free) an unanticipated high capacitance value is obtainedover prior art anodizing techniques for the intermediate voltageanodizing range of about 250-350 volts.

A preferred embodiment is provided in a capacitor comprising an aluminumanode and a dielectric layer comprising phosphate doped aluminum oxide.The capacitor has a CV Product of at least 9 μF−V/cm² of surface area at250 volts.

Yet another embodiment is provided in a process for preparing acapacitor. The process comprises forming an aluminum plate. Withoutpre-hydration the plate is contacted with an anodizing solutioncomprising glycerine, 0.1 to 2.0%, by weight, water and 0.01 to 0.5%, byweight, orthophosphate. A voltage is applied to the aluminum plate of atleast 220 volts.

Yet another embodiment is provided in process for preparing a capacitor.The process comprises forming an aluminum plate. The plate is contactedwith an anodizing solution comprising glycerine, 0.1 to 2.0%, by weight,water and 0.01 to 0.5%, by weight, orthophosphate. A voltage is appliedto the aluminum plate and an initial current is determined. The firstvoltage is maintained until a first measured current is no more than 50%of the initial current. The voltage is increased and initial currentredetermined. The increased voltage is maintained until a secondmeasured current is no more than 50% of the redetermined initialcurrent. The voltage increases and voltage maintaining are continueduntil a final voltage is achieved.

A particularly preferred embodiment is provided in a capacitorcomprising an aluminum anode and a dielectric layer comprising phosphatedoped aluminum oxide. The capacitor has a CV Product of at least 9μF−V/cm² of surface area at 250 volts. Furthermore, the capacitor isformed by the process of: forming an aluminum plate; contacting theplate with an anodizing solution comprising glycerine, 0.1 to 2.0%, byweight, water and 0.01 to 0.5%, by weight, orthophosphate; applying avoltage to the aluminum plate and determining an initial current;maintaining the first voltage until a first measured current is no morethan 50% of the initial current; increasing the voltage andredetermining the initial current; maintaining the increased voltageuntil a second measured current is no more than 50% of the redeterminedinitial current, and continuing the increasing of the voltage andmaintaining the increased voltage until a final voltage is achieved.

BRIEF SUMMARY OF THE DRAWINGS

FIG. 1 is a graph of an embodiment of the present invention illustratingthe improvement of the present invention as indicated by the graph ofμf−V/cm² as a function of voltage. The area (in cm²) is the surface areaof the anode which increases with an etched surface as known in the art.

FIG. 2 is a graph of an embodiment of the present invention illustratingthe improvement of the present invention as indicated by the graph ofμf−V/cm² as a function of voltage following heat-treatment of theanodized coupons at 400° C. for 15 minutes, followed by anodizing theoriginal voltage in the original solution for 1 hour.

FIG. 3 is a graph illustrating the impact of a hydrated surface and theabsence of the high capacitance observed when a non-hydrated surface istreated in accordance with the present invention.

DETAILED DESCRIPTION OF THE INVENTION

The inventors of the present application have found that themodification of the electrolytes described in U.S. Pat. No. 6,409,905 tobe useful for the anodizing of aluminum foil to several hundred volts.Generally speaking, glycerine solutions of ammonium, amine, or alkalimetal orthophosphate salts containing from about 0.01 wt % to about 0.5wt % soluble orthophosphate salt and from about 0.1% to about 2.0%water, more preferably about 0.1% to about 1.0% water, may besuccessfully used to anodize aluminum foil to high voltages. Lowerorthophosphate salt concentrations and higher solution resistivities arepreferably used for higher anodizing voltages in accordance with theprinciples of aluminum anodizing which have long been established bythose familiar with the art. For most high voltage applications, we havefound it to be advantageous to employ dibasic potassium phosphate as theionogen, at a preferred concentration of 0.01% to 0.1%, by weight,depending upon the maximum desired voltage.

The electrolyte soluble orthophosphate salt may be an ammoniumphosphate, an alkali metal phosphate, an amine phosphate, or mixturesthereof. Suitable alkali metal salts include, but are not limited to,mono-sodium phosphate, di-potassium phosphate, and sodium potassiumphosphate. Suitable ammonium salts include, but are not limited to,mono-ammonium phosphate or di-ammonium phosphate.

The solution temperature employed may be varied over a wide range, forexample, from room temperature, or about 25° C., to about 125° C., butthe temperature is most conveniently maintained between about 80° C. and105° C. In this range (i.e. about 80° C. and 105° C.) the water contentof the electrolyte will tend to be automatically maintained betweenabout 0.2% and 1.0% by contact with the atmosphere through the vaporpressure of the water present and the hygroscopicity of the glycerinesolvent.

It is preferable that the anode metal is placed into the anodizingsolution followed by sequentially increasing the voltage stepwise withcurrent age down prior to the next increment.

The voltage increase is preferably done in increments. The maximum sizeof the increment is chosen to be less than that necessary to createfailure in the oxide. As the resistivity of the anodizing solutionincreases the maximum voltage step which can be implemented withoutoxide failure increases. Based on the present invention, a voltage stepof less than 75 volts is preferable. Higher steps can be taken,particularly at higher voltages with high resistivity anodizingsolutions, yet the time required for adequate age down increases andtherefore no substantial benefit is observed. Smaller voltage increasescan be employed with the disadvantage being loss of efficiency. It ismost desired that the voltage increase be at least 20 volts per step tooptimise the efficiency without compromising product quality. A voltageincrease of about 50 volts for each step has been determined to beoptimal for the present invention.

After each voltage increase the voltage is maintained until a sufficientdecrease in current is realized. The more the current is allowed todecrease prior to the next voltage increase the better for efficiency ofanodization yet a decrease is observed in productivity. It is preferredthat the anode be maintained at voltage long enough to allow the currentto decrease to at least less than 50% of the original current and morepreferably at least 30% of the original current. The upper limit of holdtime for current decrease is based on efficiency. Allowing the currentto decrease to 1%, or less, of the original current is acceptable yetthe loss in efficiency exceeds the advantages obtained. It is mostpreferred that the voltage be maintained at each step for a timesufficient to allow the current to decrease to about 10-30% of theoriginal current. This has been determined to be an optimal conditionbetween suitable product and manufacturing efficiency. It has been foundthat a decrease in current to at least about 20% of the original currentat each voltage step is optimum to achieve superior product performancewith reasonable manufacturing efficiency. The current may be allowed todecrease to a low level at the last voltage step in order to obtain avery low leakage dielectric film.

The process for manufacturing a stacked foil conductive polymer is knownin the art. Specifically, stacked foil conductive polymer-containingsolid capacitors may be treated with the inventive solution to producean anodic oxide film on the edges of the coupon, repair any cracks inthe anodic oxide from handling, and impart hydration resistance to theanodic oxide already present on the coupon.

The stacked foil conductive polymer-containing solid capacitors aretypically prepared from anode foil coupons cut from etched and anodizedfoil and mounted on carrier bars, by welding or similar means, forprocessing.

In a particularly preferred embodiment coupons are cut and welded to aprocess bar. Masking is applied to prevent wicking of the materials usedto produce the conductive polymer into the weld zone of the coupons.

The coupons are then immersed in an anodizing electrolyte of the presentinvention and are processed as described above.

The edge-anodized and rinsed coupons are then ready for processing intocapacitors

Examples

A series of aluminum coupon anodizing runs was conducted using asolution of dibasic potassium phosphate, K₂HPO₄, water and glycerine,within the concentrations of the present invention, at a temperature of95° C.±5° C. The maximum voltage of each anodizing run was increased by50 volts per run, from 50 to 1000 volts. The voltage used for each runwas applied in a series of 50-volt steps. The current was allowed to“age-down” to below 20% of the initial value at each voltage step beforeagain raising the voltage.

The concentration of K₂HPO₄ varied with voltage with 0.05% being usedfor the first half of the series of coupons and 0.01% K₂HPO₄ for thehigher voltages.

The coupon capacitance was measured for each anodizing voltage and theCV product (capacitance×voltage) was calculated per Cm² of surface areathroughout the formation voltage range. The results are provided in FIG.1.

FIG. 1 shows that the CV/cm² product for plain aluminum foil isapproximately 5 microfarad-volts per square centimeter for the first 200volts, then the CV product jumps to approximately 14 and decreases backto the baseline of about 5 CV/cm² product over the next 150 volts. Thisunanticipated increase is thought to be due to a structuralrearrangement within the oxide as 250 anodizing volts are approached.Anode coupons held as long as 15 hours at voltage still show thisanomalously high CV product at 250 anodizing volts.

The anomalously high CV at 250 volts is apparent, though smaller, evenfollowing a thermal relaxation step at 400° C. (15 minutes) followed bya second anodizing step in which the coupons are held at the originalanodizing voltages for an hour, as shown in FIG. 2.

If the foil is first preboiled prior to anodizing in the electrolytes ofthe present invention, the anodizing proceeds smoothly up to very highvoltages, but the anomalous CV behaviour, at 250 volts, observed withun-preboiled foil is absent.

FIG. 3 shows the results obtained with coupons which were exposed towater at 95° C.±3° C. for 5 minutes prior to anodizing. These couponswere anodized in the same manner as those of FIG. 1. In this case the CVproduct of approximately 7 microfarad-volts/cm² is that commonly foundfor crystalline anodic aluminum oxide and no anomaly is seen.

We have, then, found that orthophosphate salt solutions in glycerine maybe used to anodize aluminum foil to at least 1000 volts.

We have found that foil anodized in these solutions exhibits ananomalously high capacitance at 250-350 volts. This anomaly is probablydue to an oxide structure change in these solutions at about the 250volt anodizing voltage.

We have demonstrated that this anomaly is not observed with “preboiled”foil.

We have found that both very high voltages (i.e., 1,000 volts) and veryhigh capacitance (at 250 volts) are made possible through the use ofsolutions which are self maintaining from the standpoint of watercontent (i.e. they stabilize at about 0.2 to 1.0% at 80-105° C.).

Furthermore, analysis of the highest-voltage solution used to preparethe coupons for FIG. 1 was found to contain only 2 ppm aluminum afterthe anodizing work was completed, signifying an almost completeelimination of the corrosion associated with prior art aqueous phosphateanodizing solutions.

The invention has been described with particular emphasis on thepreferred embodiments. It would be realized from the teachings hereinthat other embodiments, alterations, and configurations could beemployed without departing from the scope of the invention which is morespecifically set forth in the claims which are appended hereto.

1-22. (canceled)
 23. A process for preparing a capacitor comprising:forming an aluminum plate; contacting said plate with an anodizingsolution comprising glycerine, about 0.1 to about 2.0%, by weight, waterand about 0.01 to about 0.5%, by weight, orthophosphate; applying avoltage to said aluminum plate and determining an initial current;maintaining said first voltage until a first measured current is no morethan 50% of said initial current; increasing said voltage andredetermining said initial current; maintaining said increased voltageuntil a second measured current is no more than about 50% of saidredetermined initial current, and continuing said increasing saidvoltage and said maintaining said increased voltage until a finalvoltage is achieved.
 24. The process for preparing a capacitor of claim23 wherein said final voltage is above 220 volts.
 25. The process forpreparing a capacitor of claim 24 wherein said voltage is increased byno more than about 75 volts.
 26. The process for preparing a capacitorof claim 25 wherein said voltage is increased by at least about 20 V tono more than about 50 V.
 27. The process for preparing a capacitor ofclaim 23 wherein said first measured current or said second measuredcurrent is from about 1 to about 50% of said initial current.
 28. Theprocess for preparing a capacitor of claim 27 wherein said firstmeasured current or said second measured current is from about 10 toabout 30% of said initial current.
 29. The process for preparing acapacitor of claim 28 wherein said first measured current or said secondmeasured current is about 20% of said initial current.
 30. The processfor preparing a capacitor of claim 23 wherein said anodizing solution isat a temperature of about 25° C. to about 125° C.
 31. The process forpreparing a capacitor of claim 30 wherein said anodizing solution is ata temperature of about 80° C. to about 105° C.
 32. The process forforming a capacitor of claim 23 wherein said anodizing solutioncomprises about 0.01 to about 0.1% soluble orthophosphate.
 33. Theprocess for forming a capacitor of claim 23 wherein said solubleorthophosphate is selected from a group consisting of ammoniumphosphate, alkali metal phosphate, amine phosphate and mixtures thereof.34. The process for forming a capacitor of claim 23 wherein said solubleorthophosphate is selected from a group consisting of mono-sodiumphosphate, di-potassium phosphate, and sodium potassium phosphate. 35.The process for forming a capacitor of claim 23 wherein said solubleorthophosphate is selected from a group consisting of mono-ammoniumphosphate and di-ammonium phosphate. 36-40. (canceled)